Lubricating-cake and method of making same.



C. H. SHEASLEY. LUBRICATING CAKE AND METHOD 0F MAKING SAME.

APPLICATION man 1AN.22. |1916.

LUM?, Patented Apr. 25, 1916.

, www M 1,/ Ww. 40-13% CHARLES SHEASLEY, O1? FRANKLN, PENNSYLVANIEA.

LUBRICATING-CAKE AND METHOD @1F MAKING SAME.

mentar..

Specification of Letters atent.

Patented fkpr. 25, Mill@ Application led January 22, 1916. Serial 1\T o.^73,6'50.

Ta @ZZ 1li/1.0m z't 11mg/ concern.'

lie it known that l, CHARLES Il. Sunris- LEY, a citizen of the United States of America., and a resident of Franklin, Pennsylvania., have invented a new and useful limprovement in Lubricating-Cakes and Metliods of Making Same, which invention 1s fully set forth in the following spec1fica tion.

rlhis invention relates to the art of lubrication, and more particularly to lubricants designed to be employed in a solid form. lVhen solid lubricants are employed, it is desirable in many of the conditions of use, to mold the lubricant into the form of the lubricating box or other container 1n which it is to be placed for use, in order to facilitate the ready application of the lubricant. Furthermore, the lubricant must be hard in order that it may withstand high pressures and temperatures Without `undue wear or Waste. As an example, it 1s customary in applying solid lubricants to the journals of locomotive engines to employa lubricating box in Which is placed a solid cake of the lubricant previously molded to the form of the box and having a concave surface which is placed adjacent to the journal. The lubricant is applied to the journal by pressure. An example of an axle box lubricator of this typeis shown and described in U. S. Letters-Patent No. 818,022, dated April-17, 1906.

1t has heretofore been the practice to ship the solid lubricant in large masses packed in barrels or other containers. `When it is desired for use, it is either taken cold and forced into a suitable mold for giving it the desired shape, or itis remelted and cast into a mold of the proper form for this purpose. Each of these methods of molding the lubricant is open to serious objection, inasmuch as they materially change the proportions of the ingredients of which the lubricant is composed, to the detriment of its lubricating qualities, and also change the structure and lgeneral physical characteristics of the lubricant, also to the serious detriment of its lubricating qualities. lit is desirable that lubricants employed for this purpose shall contain as large an amount of mineral oil as possible. At the same time the lubricant must be hard in order to be durable and to retain the form in which it is to be applied. This has been accomplished heretofore by incorporating the mineral oil with ingredients suitable for making hard soap as, for example, tallow treated with an alkali suflicient to convert the fat into a hard soap and leave the alkali in excess, the alkali beingv introduced in the form of an alkali solution. When an attempt is made to press this lubricant into the desired form in a cold state, it is found that the pressure necessary to impart the form to the lubricant causes an exudation of Water, glycerin and alkali solution therefrom. This causes a deterioration in its lubricating qualities, since the Water, the glycerin, and the alkali solution each performs a desirable function in the lubricating body. Moreover, this cold molding produces a material change in the structure of the lubricant. lt is irregular and granular in structure, quite soft, and easily broken. The surface of the cold molded lubricant is soft, and moisture, glycerin and the alkali solution continue to exude therefrom after the molding operation is completed. In a short time after the molding operation, the alkali eiiioresces in spots on the surface as a solid incrustation which is detrimental to its lubricating qualities. Moreover, the liquid exudations cause a sticky, damp condition on the surface of the cake of lubricant which injures a pasteboard or paper packing case, renders it diiiicult to handle, and causes cinders and dirt tov adhere thereto. rllhe sum total of the results obtained by cold molding is an inferior lubricant, due to its change in physical characteristics; the parting With moisture, glycerin, and alkali solution during the pressing operation; the continued parting With these substances after the molding operation; and the incrustation of alkali upon the surface. And its durability and lubricating qualities are decreased by reason of its softness and changed structural condition.

If an attempt be made to mold the lubricant by remelting after it is once made and permitted to cool, that is, if it be taken from the container in Which it Was originally placed at the time of manufacture, remelted and then cast into a mold, it has been found that the remelting requires a temperature far exceeding that required to prepare the original composition,v and approximating in fact from 425 to 450 F. lThis high remelting temperature necessarily results in driving off a Very large part ofthe moisture contained in the lubricant, and, upon pouring the mass into a mold and allowing it to cool therein, it assumes a fine spongy condition, is soft, easily indented by the pressure of the finger, and very light. It is easily broken, dry, and ranular. The high temperature required; to melt the lubricant causes considerable decomposition, with the evolution of moisture and the pungent odor this way, and have greatly handicapped its use by cold molding. g

The object of the present invention is to provide a hard lubricant molded into suitable form for use in a lubricant container, and which shall be free from the aforementioned objections. j

llVith this object in view, the invention consists in a molded cake of lubricant and the process of manufacturing the same. The particular form in which the lubricant is molded 'will be governed by the form of the lubricant contalner or lubricant cellar in which it is designed to be used. In some cases, as for example, that shown in Patent No. 818,022 above referred to, the lubricant cellar is provided with a perforated concave top and a flat, spring-pressed follower, and the molded cake for use in such cellar should have a form in horizontal cross-,section approximatingrthat of the cellar or lubricant container. The top of the molded cake of lubricant may be either provided with a concavity corresponding to the surface to be lubricated, with the opposite side Hat, or the molded block of lubricant may have a lat top and a flat bottom. In either case the molded block of lubricant is pressed against the journal to be lubricated by the follower in the lubricant container.

I have discovered that if mineral oil be mixed with hard soap stock, such as tallow,

or the derivatives thereof capable of being converted into hard soap, and the mixture then treated with a suitable caustic alkali, as caustic soda, for saponifying the hard soap stock, the alkali being in excess, and the product cast into a suitable mold before the reaction of saponification is complete, there will result a hard, tough, durable, homogeneous molded Vcake of lubricant possessing the maximum of eiliciency asa-lubricant,

and from which neither moisture, glycerin nor alkali will exude; and which, in short, Willsnpply a highly efficient, durable lubricant 1n convenientk form ready for use, and

which will eliminate all of the objections hereinbefore described. When made accordmg to my invention, the moldedcake reference to the accompanying drawings, in

which- Figure 1 is a vertical4 cross-sectional perspectlve of a mold in which the lubricant is cast, showing the lubricant therein; Fig.2is a perspective view of the molded cake after it is taken out of the mold of Fig. 1; Fig. 3 is a cross-sectional view of a journal and the lubricating cellar or container thereof, with the cake of lubricant in position therein; and Fig. 4 is a perspective view of a molded cake of lubricant having a flat top and bottom.

In the practice of the invention, I take mineral oil and any suitable hard soap stock (such, for example, as tallow or the fatty acids thereof capable of being employed in the manufacture of hard Soap), and thoroughly mix the same under a temperature which will facilitate incorporation of the oil with the stock. I have found a temperature of 115 to 125 F. to serve this purpose. The proportions of the soap stock and mineral oil employed will depend upon the structuraly characteristics desired in the lubricant. After the mineral oil and the soap stock have been thoroughly mixed, I permit the temperature to fall'to approximately 105 F., and then treat the mass with an alkali to convert the soap stock employed into a hard soap, the alkali, such for example as caustic soda, being preferably introduced in the form of a solution composed of equal parts by weight of caustic soda and water, the quantity of the alkali solution employed being in excess, and preferably 50% in excess, of the chemical equivalent of the-soap stock used. Most excellent results are obtained by employment of the following proportions of ingredients by weight, to wit:

Tallow 14. lbs. Mineral oil 9.7 lbs. Soda lye 3. lbs. Water 3. lbs.

The alkali solution is introduced at ap-y proximately a temperature of 105 F., and preferably it is sprayed into the mixture. The entire mass is agitated during the spraying operation, and as soon as the alkali solution is sprayed into the mixture and thoroughly incorporated therewith, and before the reaction of saponification is complete, I pour the mixture into a suitable mold, and permit the reaction of saponii- `cation to be carried to completion while the mass is within the mold. The chemical reaction will cause a very marked rise in the r temperature of the mass. This temperature i, moet? will be found yto be from 175 to 250 F., depending upon the quantities of the materials employed.

Referring to Fig. 1, 1 is a mold which preferably is of pasteboard or fiber, since when such a mold is employed, the removal of the cast cake of lubricant therefrom is greatly facilitated; and 2 is the cake of lubricant therein. After the mass 'is poured into the mold l, the mold is preferably covered by any suitable cover, as for eX- ample, the cover 3 shown in dotted lines in Fig. l. The mold is provided with a con- .vex bottom el, and when the molded cake of lubricant 5 is removed from the mold, it will have the form shown in Fig. 2. lf, however, the same be cast in a mold having a flat bottom, it will have the form of the cake 6, shown in Fig. 4.

When the lubricant container is in the fo-rm of the lubricant cellar 7, shown in Fig. 3, said cellar is sometimes, though not necessarily, provided with a perforated cap portion 8 having a concave upper surface conforming to the cylindrical outline of the journal 9. Preferably,`cake 5 of Fig. -2 is used in this form of lubricant container, the same being supported upon the follower 10 pressed upward by the spring 11. When such cake has been largely consumed so as to leave only the upper concave portion unconsumed, it may be either removed and another similar cake inserted in its place, or the flat cake 6 of Fig. 4 may be placed under the unconsumed portion of the lubricant cakein the cellar without removing the same, thus effecting the economical consumption of all of the lubricant. lf desired, the flat cake 6 might be employed in the first instance, and the concavity worn therein as the cake is consumed, but as indicated above, ll prefer to start the operation with the cake 5 of Fig. 2.

lt will be apparent that if the lubricant were molded into a cake say double the length desired for use in the lubricant container, and then c ut in two to form two cakes of equal size, it would still be within the spirit of my invention, though the surface where the cut occurred would not be a. case-hardened surface, and ll therefore prefer to cast the lubricant in the form of single cakes ready for use. Nevertheless, l desire it distinctly understood that a cake molded to form by pouring the lubricant into a moldl during the reaction of saponiiication, and then cut into proper lengths suitable for use in a lubricant container would be within the purview of my invencant are superior to any results obtained when the lubricant is cold molded under pressure, and the durability of the lubricant 1s increased by approximately 50%. As indlcated above, if the lubricant is remelted and then molded, its lubricating properties are practically destroyed.

.When a lubricant is made in accordance w1t'h my invention, it retains all of the molstureoriginally introduced therein and the product of saponification, whether glycerin or water, resulting from the chemical reaction of the alkali on the soap stock, and the excess alkali is uniformly distributed thoughout the mass and emulsifes the mineral oil. Moreover, the molded cake of lubricant will be found to have a glazed or casehardened surface, which efectually occludes the moisture, the glycerin and the alkali within the cake, therebypreventing the loss of the moisture by evaporation, and exudation of the glycerin and alkali, and consequent eiioresence of the latter. The mass of the lubricant is of a uniform and homogeneous texture, non-granular, tough and hard. 'llhese properties materially contribute to the efiiciency of the mass as a lubricant, and to its lasting and wearing properties, thus making not only for effectiveness in lubrication, but economy in use. lts durability results from its compact and uniform structure and the retention of its constituents in their original proportions and its adaptability to the incorporation of a large quantity of mineral oil, while still retaining its structural form.

From the foregoing, it will be perceived that I have provided a lubricant molded into suitable form for use in the lubricant container, and in which the proportions and the constituents of the original lubricant are retained in the molded cake; and which employs a large amount of mineral oil, recognized asdesirable in such lubricants, and which is hard in texture, tough and durable. So far as I am informed, this has never before been accomplished.

It will be understood by those skilled in the art that the proportions of ingredients and the temperatures herein indicated may be varied within limits, and such proportions and temperatures are herein given for the purpose of clearly describing the invention, and not for the purpose of defining the limits thereof, reference being had to the claims for this purpose.

What is claimed is 1. The process of making a lubricant cake for a lubricant container consisting in mixing hard soap stock, mineral oil and excess. of alkali solution, then pouring the mixture into a lubricant cake mold to saponify and solidify therein. I

2. The method of making a solid lubricant cake for use in lubricant containers,

which 'consists in mixing together mineral oil, hard soap stock and an alkali solution, the alkali being in excess, and then molding the mass into suitable form for use in a lubricant container during the reaction of saponificatiqn.

3. The method of making a solid lubricant cake for use in lubricant containers, which consists in mixing together in the presence of heat mineral oil, hard soap stock and an alkali solution, theI alkali-being in excess, and then casting the, mass into suitable form for use in a lubricant container before the reaction of saponication is complete.

4. The method of making a lubricant cake for a lubricant container, Which consists in mixing mineral oil and hard soap stock at a temperature of approximately 125o F., then lowering the temperature to approximately 1059 F., then introducing alkali in solution at approximately 105 F., the alkali being in excess of the amount necessary to saponify the soap stock, and then before the reaction of saponication is complete pouring the mass into a mold having the form of the container.

5. The method of making a lubricant cake for a lubricant'container, consisting in mixing hard soap stock and mineral oil at a temperature of approximately 125 F., then lowering the temperature to approximately 105o F., then introducing alkali in solution at approximately 105 F., the alkali being in excess of the amount necessary to saponify the soap stock whereby the temperature of the mass Will be raised as the result of the reaction, and then before the reaction of saponiication is complete pouring the mass into a mold having the form of the container. i.

6. The method of` making a lubricant cake for a lubricant container, which consists in mixing mineral oil and a hard soap stock in the presence lof heat, then introducing alkah in .solution into theV mass, and then before the reaction of saponication is complete ,p

pouring the mass into a mold having the form of the container.

7. A' cast cake of lubricant for use in a lubricant container, said cake consisting of mineral oil, soap associated with the product of its saponification and an alkali solution,

the same being cast direct from the lfluid state of its original manufacture into suitable form for use in said container.

8. A cast cake of lubricant for use in a lubricant container, said cake consisting of mineral oil, soap associated With the product of its saponification and an alkali solution, the same being cast during the saponifying reaction of its manufacture intosuitable form for insertion in said container.

`9. A cast cake of lubricant for use ina lubricant container, said cake containing mineral oil, hard soap`and free alkali, the same being cast during the saponifying reaction of its manufacture into suitable form for insertion in said container.

10. A cast cake of lubricant for use in a lubricant container, said cake containing mineral oil and hard soap and being cast during the saponifying reaction of its manufacture into suitable form for insertion in said container.

11. A case-hardened cast cake of lubricant for use in a lubricant container, said cake containing mineral oil, hard soap and free alkali, the same being cast during the saponifying reaction of its manufacture into suitable form for insertion in said container.

12. A cast cake of lubricant for use in a lubricant container and having a form to fit the lubricant container, said cakeV containing mineral oil, hard soap and free alkali and having the physical characteristics resulting from the saponifying reaction.

13. A cast lubricant for use in a lubricant container and having a form to fit the lubricant container, said cake containing mineral oil and hard soap and having the molecular arrangement assumed on solidifying at the close of the saponifying reaction.

14. A cast cake of lubricant for use in a lubricant container, said cake consisting of mineral oil, soap associated with the glycerin of saponiication, and an alkali solution, the same being cast during the saponifying reaction of its manufacture into suitable form for insertion in said container.

15. A case-hardened cast cake of lubricant for use in the lubricant container of a locomotive or the like, said cake containing mineral oil, hard soap and free alkali and having a form to fit the lubricant container.

16. A case-hardened cast cake of lubricant for use in the lubricant container of a locomotive or the like, said cake consisting of mineral oil, hard soap associated with the glycerinl of saponification and an alkali solution and having a form to Iit the lubricant container.

17. A cast cake of lubricant for use in a lubricant container and having a form to fit the lubricant container, said cake being of a dense uniform structure throughout its mass and consisting-of mineral oil, soap associated with the product of its saponication and an alkali solution.

18. A cast cake of lubricant for use in a lubricant container and having a form to t the lubricant container, said cake consisting of mineral oil, soap associated withl Medea? kali solution and having all the physical characteristics resulting from the saponify-A ing reaction:

' 19. A cast cake of lubricant for use in a lubricant container, saidrcake` containing rr'llineraloil, soap associated with the product .of saponifcation and an alkali solution,

said elements having the relative molecular arrangement assumed on solidifying'at the 10 close of -the saponifying reaction.

20. A cast cake of lubricant for use in a lubricant container, said cake containing mineral oil, 'hard soap-associated with the glycerin of saponification and an alkali so` lutOn, said elements having the relative molecular arrangement assumed on solidifying at the close of the saponifying reaction. ln testimony whereof l have signed this specification.

CHARLES H. SHEASLEY. 

